Apparatus and method usable with an injection molder for producing articles

ABSTRACT

An apparatus usable with an injection molder for producing articles includes a first mold support including a first mold, and a second mold support including a second mold and a first die. The first mold support is movable relative to the second mold support between a first and a second position. In the first position, the first mold and the second mold being brought together to form an injection molded article having at least one protrusion extending outwardly from the body and facing the second mold. In the second position, the first mold and the first die being brought together to subsequently form the article, the first die selectively subsequently forming an altered cross sectional region in the protrusion, forming an undercut in the altered cross sectional region or between the altered cross sectional region of the subsequently formed protrusion and the body, each article being separate and non-interlocking.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. ProvisionalApplication No. 61/751,591 filed Jan. 11, 2013, and to U.S.Non-provisional application Ser. No. 14/153,269 filed Jan. 13, 2014,each of which is hereby incorporated by reference in its entirety.

FIELD

The present invention relates to orthodontic articles and moreparticularly to orthodontic brackets.

BACKGROUND

In the past, various difficulties have been encountered in connectionwith the orthodontic necessity to apply corrective appliances to humanteeth pursuant to which certain teeth are displaced to a position ofbetter alignment, and/or occlusion.

One primary need in orthodontic corrections is the maintenance ofrelatively high tensile forces on the teeth, particularly in cases wheresubstantial displacements are required.

In response, brackets have been utilized, i.e., wire guiding and wireanchoring means which do not encircle individual teeth. However, therecontinue to be challenges associated with such brackets, which aredifficult to apply since the cold curing cement used to affix thebrackets to the teeth does not adhere well to the brackets. In practice,this inadequate adhesion has resulted in the application of reducedforces, reducing the effectiveness of orthodontic corrective treatment.

There is a need in the art for an apparatus and method for reliablyincreasing adherence of orthodontic brackets to teeth surfaces for usein orthodontic corrective treatment.

SUMMARY

In an exemplary embodiment, an apparatus usable with an injection molderfor producing articles, includes a first mold support comprising a firstmold, and a second mold support comprising a second mold and a firstdie. The apparatus further includes the first mold support movablerelative to the second mold support between a first position and asecond position. The apparatus further includes in the first position,the first mold and the second mold being brought together to form aninjection molded article comprising a body having at least oneprotrusion extending outwardly from the body and facing the second mold.The apparatus further includes in the second position, the first moldand the first die being brought together to form a subsequently formedarticle, the first die selectively subsequently forming a first alteredcross sectional region in at least a first portion of the protrusion,forming a first undercut in the first altered cross sectional region orbetween the first altered cross sectional region of the protrusion andthe body. The apparatus further includes the first undercut proximate toan end of the protrusion, the first die adapted to form a second alteredcross sectional region in at least a second portion of the protrusion,forming a second undercut, the second undercut non-proximate to the endof the protrusion. The apparatus further includes each article beingseparate and non-interlocking relative to one another.

In another exemplary embodiment, an apparatus usable with an injectionmolder for producing articles, includes a first mold support comprisingat least two first molds. The apparatus further includes a second moldsupport comprising at least two second molds and at least two firstdies. The apparatus further includes the first mold support rotatablymovable relative to the second mold support between a first position anda second position. The apparatus further includes in the first position,each of the corresponding first molds and second molds being broughttogether to form an injection molded article comprising a body having atleast one protrusion extending outwardly from the body and facing thesecond mold. The apparatus further includes in the second position, eachof the corresponding first molds and first dies being brought togetherto form a subsequently formed article, each first die selectivelysubsequently forming a first altered cross sectional region in at leasta first portion of the protrusion. The apparatus further includesforming a first undercut in the first altered cross sectional region orbetween the first altered cross sectional region of the protrusion andthe body, the first undercut proximate to an end of the protrusion. Theapparatus further includes the first die adapted to form a secondaltered cross sectional region in at least a second portion of theprotrusion, forming a second undercut, the second undercut non-proximateto the end of the protrusion. The apparatus further includes eacharticle being separate and non-interlocking relative to one another.

In another exemplary embodiment, a method of producing injection moldedarticles, includes providing a first mold support comprising a firstmold, a second mold support comprising a second mold and a first die.The method further includes bringing the first mold support and thesecond mold support together in a first position, the first mold and thesecond mold being brought together to form an injection molded articletherebetween, each article being separate and non-interlocking relativeto one another, the article having at least one protrusion facing thesecond mold. The method further includes moving the first mold supportaway from the second mold support, and moving the first mold supportrelative to the second mold support. The method further includesbringing the first mold support and the second mold support together ina second position, the first mold and the first die being broughttogether to form a subsequently formed article, the first dieselectively subsequently forming a first altered cross sectional regionin at least a first portion of the protrusion, forming a first undercutin the first altered cross sectional region or between the first alteredcross sectional region of the protrusion and the body, the firstundercut proximate to an end of the protrusion, the first die adapted toform a second altered cross sectional region in at least a secondportion of the protrusion, forming a second undercut, the secondundercut non-proximate to the end of the protrusion.

Other features and advantages of the present invention will be apparentfrom the following more detailed description of the preferredembodiment, taken in conjunction with the accompanying drawings whichillustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a lower perspective view of an exemplary injection molder andapparatus according to the disclosure.

FIG. 2 is an upper perspective view of an exemplary apparatus in an openposition and an exemplary mold in a first position according to thedisclosure.

FIG. 3 is an enlarged, partial view of an exemplary mold taken fromregion 3 of FIG. 2 according to the disclosure.

FIG. 4 is a reverse upper perspective view, relative to FIG. 2, of theexemplary apparatus of FIG. 2 according to the disclosure.

FIG. 5 is an enlarged, partial view of an exemplary mold taken fromregion 5 of FIG. 4 according to the disclosure.

FIG. 6 is a further enlarged, partial view of an exemplary mold takenfrom region 6 of FIG. 5 according to the disclosure.

FIG. 7 is an enlarged, partial view of an exemplary die taken fromregion 7 of FIG. 5 according to the disclosure.

FIG. 8 is an upper perspective view of an exemplary apparatus in aclosed position according to the disclosure.

FIG. 9 is an upper perspective view of an exemplary apparatus in an openposition according to the disclosure.

FIG. 10 is an enlarged, partial view of an exemplary initially formedarticle taken from region 10 of FIG. 9 according to the disclosure.

FIG. 11 is an enlarged, partial view of the exemplary initially formedarticle taken from region 11 of FIG. 10 according to the disclosure.

FIG. 12 is an upper perspective view of an exemplary apparatus in anopen position and an exemplary mold moving between a first position anda second position according to the disclosure.

FIG. 13 is an upper perspective view of the exemplary apparatus in anopen position and the exemplary mold of FIG. 12 in the second positionaccording to the disclosure.

FIG. 14 is an upper perspective view of the exemplary apparatus of FIG.13 in a closed position according to the disclosure.

FIG. 15 is an upper perspective view of the exemplary apparatus in anopen position in the exemplary mold of FIG. 13 according to thedisclosure.

FIG. 16 is an enlarged, partial view taken from region 16 of FIG. 15according to the disclosure.

FIG. 17 is an enlarged view of an exemplary subsequently formed articleof FIG. 16 according to the disclosure.

FIG. 18 is an upper perspective view of an exemplary (subsequentlyformed) orthodontic bracket of FIG. 16 according to the disclosure.

FIG. 19 is an enlarged, partial view of the orthodontic bracket of FIG.18 according to the disclosure.

FIG. 20 is an upper perspective view of an exemplary apparatus in anopen position and an exemplary mold in a first position according to thedisclosure.

FIG. 21 is a reverse upper perspective view, relative to FIG. 20, of theexemplary apparatus of FIG. 20 according to the disclosure.

FIG. 22 is a process diagram corresponding with the operation of anexemplary apparatus according to the disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Exemplary embodiments are directed to apparatus and method usable withan injection molder for producing articles, such as orthodontic bracketscomprising bodies having at least one protrusion extending outwardlyfrom the corresponding bodies. An altered cross sectional region isformed in at least a portion of at least one protrusion, forming anundercut in the altered cross sectional region or between the alteredcross sectional region of the at least one protrusion and the body, aswill be discussed in further detail below. The undercut providesenhanced adherence of the subsequently formed orthodontic brackets toteeth surfaces for use in orthodontic corrective treatment.

For purposes herein, an undercut is intended to correspond to an alteredcross sectional region formed in a protrusion that is positioned in thealtered cross sectional region or between the altered cross sectionalregion of the protrusion and the body of an article. Stated another way,in or coincident with the altered cross sectional region or between thebody of an article and the altered cross sectional region of aprotrusion extending outwardly from the body, the protrusion of asubsequently formed article includes a subsequently formed portionhaving at least a localized altered cross sectional area relative to thecross sectional area of the protrusion. When the localized altered crosssectional region is greater than the cross sectional area of theprotrusion, the undercut or region of reduced cross sectional area ispositioned between the localized altered cross sectional region and thebody. However, when the localized altered cross sectional region is lessthan the cross sectional area of the protrusion, the undercutcorresponds to the localized altered cross sectional region itself, suchas at least a partial recess formed in the side surface of theprotrusion.

Neither arrangement can be produced by conventional molds of aninjection molder, as a die constructed to produce protrusions havingundercuts cannot be nondestructively separated from correspondinginjection molded articles (i.e., the corresponding rigid injectionmolded articles would be destroyed while separating the molds producingthe article).

As shown in FIG. 1, an injection molder 10 includes an apparatus 12further including mold supports 18, 20 (FIG. 2) in a closed position 60.Injection molder 10, which is well known in the art, is not furtherdiscussed.

As collectively shown in FIGS. 2 and 3, mold supports 18, 20 are shownin an open position 62, versus closed position 60 (FIG. 1), movablealong a line of engagement 11 between mold support alignment features34, 36, such as respective mating openings and pins formed in moldsupports 18, 20. Mold support 18 includes mold support portions 22, 24,in which mold support portion 22 can be selectively urged intorotational movement 30, relative to mold support 20, about an axis 28extending through a center 26 of mold support portion 22. As furthershown in FIG. 2, mold support portion 24 structurally supports aplurality of molds 32 (four molds 32 are shown in FIG. 2) arranged in afirst position 56. In other embodiments, as few as one mold, or morethan four molds may be supported by mold support portion 24. As furthershown in FIG. 2, for purposes of describing the operation of theapparatus of the present disclosure, mold 32 associated with a numeral 1enclosed in a box and located at a 12 o'clock position in FIG. 2 isprimarily discussed herein and is associated with first position 56(although FIG. 2 shows additional molds 32 associated with respectivenumerals 2, 3 and 4 located at respective 3 o'clock, 6 o'clock and 9o'clock positions). As shown in further detail in FIG. 3, mold 32includes mold segments 32 a, 32 b, 32 c, 32 d that are slidablystructurally supported by a guide 38. In one embodiment, mold 32 may beof unitary or one-piece construction (i.e., having no mold segments),although in other embodiments, mold 32 may include less than four ormore than four mold segments, as required. As further shown in FIG. 3,mold segments 32 a, 32 b, 32 c, 32 d collectively define a cavity 40 forforming an article 14 by injection molding. In addition, mold support 20includes a mold 44 (FIGS. 4-6) for use in forming article 14, as furtherdiscussed below.

As further shown in FIGS. 4-7, mold support 20 includes a mold/diesupport portion 42 structurally supporting a pair of molds 44 associatedwith respective boxed numerals 1 and 3 located at respective 12 o'clockand 6 o'clock positions (FIG. 4). As further shown in FIGS. 5 and 6,mold 44 associated with boxed numeral 1 in the 12 o'clock position (FIG.4) corresponds to mold 32 in the 12 o'clock position (FIG. 3) which arebrought together (e.g., as shown in FIG. 8) to form article 14therebetween in first position 56 of mold 32 of mold support 18, withmold 32 defining cavity 40 (FIG. 3) and mold 44 including a mold surface46 (FIG. 6). As further shown in FIGS. 4, 5 and 7, mold/die supportportion 42 of mold support 20 also structurally supports a pair of dies48 associated with respective boxed numerals 2 and 4 located atrespective 9 o'clock and 3 o'clock positions (FIG. 4). Die 48 includes aperipheral recess 50 (FIG. 7), providing an outwardly extending member52 that terminates at a die surface 54. As will be discussed in moredetail below, die 48 (FIGS. 4, 5, 7) associated with boxed numeral 2located at the 9 o'clock position is brought together (e.g., as shown inFIG. 14) with the corresponding mold 32 (FIG. 13) to subsequently formand thereby transforming article 14 to subsequently formed article 16.

In one embodiment, mold support 20 structurally supports one mold 44 andone die 48, while in another embodiment, mold support 20 structurallysupports more than two molds 44 and more than two dies 48.

In operation, as shown in FIG. 8, with mold supports 18, 20 secured inclosed position 60 (FIG. 8), mold 32 associated with boxed numeral 1 inthe 12 o'clock position in first position 56 and mold 44 associated withboxed numeral 1 in the 12 o'clock position of mold support 20 (FIG. 4)receives injected material (not shown), forming injection molded article14, as shown with mold supports 18, 20 secured in open position 62 (FIG.9). As further shown in FIGS. 10 and 11, injection molded article 14includes a body 15 that is secured in cavity 40 of mold segments 32 a,32 b, 32 c, 32 d of mold segment 32. As further shown in FIG. 11, as aresult of mold surface 46 of mold 44 (FIG. 6), the corresponding surfaceof article 14 includes a plurality of protrusions 21 extending outwardlyfrom body 15, such as substantially circular protrusions 21 a andsubstantially ovular protrusions 21 b. However, for each of protrusions21, the profile formed is cylindrical. That is, the cross sectionalareas of protrusions 21 are either constant over the length of theprotrusions, or the cross sectional areas of protrusions 21 are tapered.That is, the cross sectional areas of the protrusions decrease as thedistance from body 15 increases. In one embodiment, one or more of theprotrusions may contain segments of constant cross section incombination with segments having decreasing cross sectional area as thedistance from the body increases (tapered profile). In one embodiment,one or more of the protrusions may extend outwardly from the body adifferent length from other protrusions. These cross sectionalconstraints of protrusions 21 are required for proper operation(clearance to permit mold removal from the rigid injection moldedarticle) during the injection molding process as previously discussed.

In one embodiment, while mold 32 associated with the 12 o'clock position(FIG. 9) and mold 44 associated with the 12 o'clock position (FIG. 5)are forming an injection molded article 14, substantiallysimultaneously, mold 32 associated with the 6 o'clock position (FIG. 9)and mold 44 associated with the 6 o'clock position (FIG. 5) are alsoforming an injection molded article 14, as previously discussed.

Once injection molded article 14 has been formed as discussed above, asfurther shown in FIGS. 12-13, mold supports 18, 20 are urged toward openposition 62 and mold support portion 22 of mold support 18 is urged intorotational movement 30 about axis 28 (from first position 56 to secondposition 58). In second position 58, mold 32 associated with numeral 1is rotated clockwise from the 12 o'clock position (FIG. 9) to the 3o'clock position (FIG. 13). In one embodiment, mold 32 may be configuredto rotate in a counter-clockwise direction.

Once mold 32 associated with numeral 1 has been rotated clockwise fromthe 12 o'clock position (FIG. 9) to the 3 o'clock position (FIG. 13),mold supports 18, 20 are brought to closed position 60 (FIG. 14). Priorto mold supports 18, 20 being urged away from each other to openposition 62 (FIGS. 15, 16), mold 32 is associated with numeral 1 and inthe 3 o'clock position (with mold supports 18, 20 in closed position 60)and mold supports 18, 20 are brought together with die surface 54 of die48 associated with numeral 2 and in the 9 o'clock position (FIGS. 4, 5,7)). As a result, die surface 54 of die 48 creates subsequently formedprotrusions 17 of subsequently formed article 16 (formerly injectionmolded article 14).

In one embodiment, while mold 32 associated with the 3 o'clock position(FIG. 15) and die 48 associated with the 9 o'clock position (FIG. 5) arecreating a subsequently formed article 16, substantially simultaneously,mold 32 associated with the 9 o'clock position (FIG. 9) and die 48associated with the 3 o'clock position (FIG. 5) are also creating asubsequently formed article 16, as previously discussed.

In one embodiment, while molds 32 are brought together withcorresponding molds 44 to form injection molded articles 14,substantially simultaneously, the remaining molds 32 are broughttogether with corresponding dies 48 to create subsequently formedarticles 16. In other words, apparatus 12 can operate continuously toform or create subsequently formed articles 16 (from previously formedinjection molded articles 14) while substantially simultaneously formingadditional articles 14. That is, with each 90 degree rotation of moldsupport portion 22 of mold support 18 relative to mold support 20, onepair of injection molded articles 14 are created, and one pair ofsubsequently formed articles 16 are formed or created continuously bythe apparatus of the present disclosure.

As further shown in FIGS. 18 and 19, in which subsequently formedarticle 16 has been ejected from the injection molder, the differencesbetween injection molded articles 14 and subsequently formed articles 16are readily apparent and significant. That is, as shown in FIG. 11,injection molded article 14 includes protrusions 21, includingprotrusions 21 a, 21 b each having cylindrical profiles (i.e., definingconstant cross sectional areas over the length of the protrusions, or adecrease in cross sectional areas over the length of the protrusions asthe distance from body 15 increases) for reasons as previouslydiscussed. In contrast, as further shown in FIGS. 18 and 19,subsequently formed article 16 includes subsequently formed protrusions17, including subsequently formed protrusions 17 a, 17 b, having anundercut 19 formed in an altered cross sectional region 64 or betweenaltered cross sectional region 64 of protrusion 17, such as in closeproximity to an end 66, and body 15, such as when the altered crosssectional region has a cross sectional area greater than the crosssectional area of the protrusion (in which case undercut 19 is formedbetween altered cross sectional region 64 and body 15). In oneembodiment, altered cross sectional region 64 is at least a localizedregion of enlarged cross sectional area relative to the cross sectionalarea of the protrusion. In one embodiment, altered cross sectionalregion 64 of protrusion 17 is not in close proximity to end 66 of body15. In one embodiment, such as shown in FIG. 19, altered cross sectionalregion 64 is at least a localized region of reduced cross sectional arearelative to the cross sectional area of the protrusion forming undercut19, so long as the localized region is not at or in such close proximityto end 66 so as not to provide a basis for improved adhesion between anadhesive and the protrusion. The formation of an undercut 19 provides abasis for improved adhesion of a surface including the subsequentlyformed protrusions 17, as hardened adhesive material may form aninterference fit defined by the difference in cross sectional areabetween the undercut and a corresponding altered cross sectional region64, such as an undercut 70 when the altered cross sectional region 64has a greater cross sectional area than the undercut. However, when thealtered cross sectional region 64 has a reduced cross sectional arearelative to the cross sectional area of the protrusion (and notproximate to end 66), the undercut 19 is formed in or is coincident withthe altered cross sectional region 64 and having an undercut depth 72.

In one embodiment, protrusions 17 can define a closed geometry, such asa substantially circular or substantially ovular profile, while inanother embodiment, protrusions 17 can define an open geometry, such asa profile similar to a crescent moon, or any suitable shape. Theprotrusions may be positioned in any suitable arrangement relative toone another, singly or collectively.

It is to be understood that the profile of the die surface of the die isnot limited to closely resemble the protrusion profile formed in theinjection molded article 14, so long as the profiles of the subsequentlyformed protrusions 17 have a desired undercut profile. That is, in oneembodiment, the position of altered cross sectional regions can beformed in a position other than the end or in close proximity to the endof the subsequently formed protrusions, if desired. In anotherembodiment, the position of the die surface is movable relative to themold support. That is, the die surface may be positioned at a desiredspacing from the protrusion surface of the injection molded article whenthe corresponding mold supports are brought together, which spacingincludes positioning the die surface such that a selective amount ofinterference or abutment occurs between ends of one or more protrusionsof the injection molded article 14 and the die surface, such that thesubsequently formed protrusion(s) is selectively controllable. In oneembodiment, a non abutting spacing remains between the die surface andthe corresponding surface of the injection molded article 14 when themold supports are brought together.

In addition, the die can be brought into a predetermined range of atleast one position relative to the protrusion(s) of the injection moldedarticle for a corresponding predetermined range of time for subjectingat least a portion of the protrusion(s) to one or more of apredetermined temperature range and a predetermined pressure range forforming the undercut. That is, the temperature of the die (of course,including the die surface) can be selectively controlled as a functionof distance or proximity of the die from the protrusion(s) of theinjection molded article in combination with a predetermined rate oftime. In addition, the temperature of portions of the die can beselectably controlled over a predetermined range of temperatures as wellas a predetermined rate of time. In other words, the temperature of thedie (and even portions of the die) can be selectively controlled incombination with the speed of travel of the die (toward and/or away fromprotrusion(s) of the injection molded article; such speeds not limitedto being the same in either direction) and/or the amount of proximity orspacing from the protrusion(s), including a range of abutment betweenthe die and the protrusion(s) of the injection molded article. Statedanother way, the die can be selectively controlled over a broad range oftemperatures, such temperatures also being selectively controllablerelative to the speed and/or distance from the protrusion(s), includinginterference or abutment, as well as selective control of time. In oneembodiment, the die may be configured to remain in a non-moving position(also referred to as dwell time) for at least a portion of the time thatthe mold supports are brought together. In one embodiment, the dieselectively controls a surface feature of at least a portion of theprotrusion(s). For example, if the die surface contacts theprotrusion(s), the surface roughness of the die may be transferred atleast to the extent of the amount of contact of the protrusion(s) andthe die surface. As a result of the extent of control of the dierelative to the protrusion(s) of the injection molded article, at leastthe position and magnitude of undercut may be selectively controlled forthe protrusion(s), and the amount of subsequent forming of theprotrusion(s) may be altered during production.

It is also to be understood that materials which may be used in theapparatus can be liquid or powdered forms of ceramic, metal, plasticmaterial or a combination thereof, depending upon the application.

It is also to be understood that while the article disclosed is anorthodontic bracket, the apparatus of the present disclosure may also beused for any number of other injection molded articles in which asecondary forming operation subsequent to production of the injectionmolded article can provide beneficial effects, not being limited toforming undercuts, such as surface features or other beneficialproperties derivable from such secondary forming operations.

As shown in FIGS. 20 and 21, in a manner similar to that previouslydiscussed, apparatus 112 includes a mold support 118 having a mold 132and a mold support 120 having a mold 144 and the die 148, with moldsupport 118 being movable between a first position 156 and a secondposition 158 relative to mold support 120. As shown in FIG. 20, moldsupport 122 can be urged into directional movement 106, which movementbeing linear, or curvilinear, if desired. In a manner similar to thatpreviously discussed, in response to movement of mold support 122 and/orof line of engagement 102, 104 between mold supports 118, 120, mold 132and mold 144 can be aligned and brought together for forming aninjection molded article 14, or mold 132 and die 148 can be aligned andbrought together for subsequently forming article 16 (formerly injectionmolded article 14).

As shown in FIG. 22, a method of producing injection molded articlesincludes providing a first mold support 18 comprising a first mold 32 instep 170. In addition, step 172 includes providing a second mold support20 comprising a second mold 44 and a first die 48. Once the componentsof steps 170 and 172 have been completed, step 174 includes bringing thefirst mold support 18 and the second mold support 20 together to form aninjection molded article 14 therebetween, the article 14 having a body15 having at least one protrusion 21 facing the second mold 44. Afterinjection molded article 14 has been formed, the first mold support 18is moved away from the second mold support 20 in step 176. Once thefirst mold support 18 has been moved away from the second mold support20, the first mold support 18 is moved relative to the second moldsupport 20 in step 178. Once the first mold support 18 is moved relativeto the second mold support 20, in step 180, the first mold support 18and the second mold support 20 are brought together to subsequently format least a portion of the subsequently formed protrusion 17 (previouslythe protrusion 21 of injection molded article 14), the first die 48selectively subsequently forming at least a portion of the subsequentlyformed protrusion 17, forming an undercut 19 between an end 66 of thesubsequently formed protrusion 21 and the body 15.

While the foregoing specification illustrates and describes exemplaryembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material including dopants to the teachings of the invention withoutdeparting from the essential scope thereof. Therefore, it is intendedthat the invention not be limited to the particular embodiment disclosedas the best mode contemplated for carrying out this invention, but thatthe invention will include all embodiments falling within the scope ofthe appended claims.

What is claimed is:
 1. An apparatus usable with an injection molder forproducing articles, comprising: a first mold support comprising a firstmold; a second mold support comprising a second mold and a first die;the first mold support movable relative to the second mold supportbetween a first position and a second position; wherein in the firstposition, the first mold and the second mold being brought together toform an injection molded article comprising a body having at least oneprotrusion extending outwardly from the body and facing the second mold;wherein in the second position, the first mold and the first die beingbrought together to form a subsequently formed article, the first dieselectively subsequently forming a first altered cross sectional regionin at least a first portion of the protrusion, forming a first undercutin the first altered cross sectional region or between the first alteredcross sectional region of the protrusion and the body, the firstundercut proximate to an end of the protrusion, the first die adapted toform a second altered cross sectional region in at least a secondportion of the protrusion, forming a second undercut, the secondundercut non-proximate to the end of the protrusion; wherein eacharticle being separate and non-interlocking relative to one another. 2.The apparatus of claim 1, wherein the first mold support is rotatablymovable about an axis relative to the second mold support.
 3. Theapparatus of claim 1, wherein the first mold support is movable along aline relative to the second mold support.
 4. The apparatus of claim 1,wherein at least the first mold support comprises a plurality of firstmolds and the second mold support comprises at least one second mold andat least one first die, the apparatus operable such that once at leastone first mold and at least one second mold have been brought togetherto form the article (the first position), when the at least one firstmold and the at least one first die are then brought together to formthe subsequently formed article (the second position), another of the atleast one first mold and another of the at least one second mold aresubstantially simultaneously brought together to form another article (athird position).
 5. The apparatus of claim 4, wherein the correspondingfirst molds, second mold(s) and first die(s) of the apparatus operatecontinuously to form subsequently formed articles while substantiallysimultaneously forming additional articles.
 6. The apparatus of claim 1,wherein the protrusion comprises an open geometry.
 7. The apparatus ofclaim 1, wherein the protrusion comprises a closed geometry.
 8. Theapparatus of claim 1, wherein the first die is brought into apredetermined range of at least one position relative to the protrusionfor a corresponding predetermined range of time for subjecting the atleast a first portion and the at least a second portion of theprotrusion to one or more of a predetermined temperature range and apredetermined pressure range for forming the first undercut and thesecond undercut.
 9. The apparatus of claim 8, wherein the temperature ofportions of the first die is selectively controllable for thepredetermined range of at least one position and the correspondingpredetermined range of time.
 10. The apparatus of claim 1, wherein thearticle is formed from a ceramic, metal, plastic material or acombination thereof.
 11. The apparatus of claim 8, wherein the first dieselectively controls a surface feature of at least one of the at least afirst portion and the at least a second portion of the protrusion. 12.The apparatus of claim 1, wherein the article is an orthodontic bracket.13. An apparatus usable with an injection molder for producing articles,comprising: a first mold support comprising at least two first molds; asecond mold support comprising at least two second molds and at leasttwo first dies; the first mold support rotatably movable relative to thesecond mold support between a first position and a second position;wherein in the first position, each of the corresponding first molds andsecond molds being brought together to form an injection molded articlecomprising a body having at least one protrusion extending outwardlyfrom the body and facing the second mold; wherein in the secondposition, each of the corresponding first molds and first dies beingbrought together to form a subsequently formed article, each first dieselectively subsequently forming a first altered cross sectional regionin at least a first portion of the protrusion, forming a first undercutin the first altered cross sectional region or between the first alteredcross sectional region of the protrusion and the body, the firstundercut proximate to an end of the protrusion, the first die adapted toform a second altered cross sectional region in at least a secondportion of the protrusion, forming a second undercut, the secondundercut non-proximate to the end of the protrusion; wherein eacharticle being separate and non-interlocking relative to one another. 14.The apparatus of claim 13, wherein the corresponding first molds, secondmolds and first dies of the apparatus operate continuously to formsubsequently formed articles while substantially simultaneously formingadditional articles.
 15. The apparatus of claim 13, wherein each firstdie is brought into a predetermined range of at least one positionrelative to the corresponding protrusion for a correspondingpredetermined range of time for subjecting the at least a first portionand the at least a second portion of the protrusion to one or more of apredetermined temperature range and a predetermined pressure range forforming the undercut.
 16. The apparatus of claim 15, wherein thetemperature of portions of the first die is selectively controllable forthe predetermined range of at least one position and the correspondingpredetermined range of time.
 17. The apparatus of claim 13, wherein thearticle is formed from a ceramic, a metal, a plastic or a combinationthereof.
 18. The apparatus of claim 15, wherein the first dieselectively controls a surface feature of the at least a first portionand the at least a second portion of the protrusion.
 19. The apparatusof claim 13, wherein the article is an orthodontic bracket.
 20. A methodof producing injection molded articles, comprising: providing a firstmold support comprising a first mold, a second mold support comprising asecond mold and a first die, bringing the first mold support and thesecond mold support together in a first position, the first mold and thesecond mold being brought together to form an injection molded articletherebetween, wherein each article being separate and non-interlockingrelative to one another, the article having at least one protrusionfacing the second mold; moving the first mold support away from thesecond mold support; moving the first mold support relative to thesecond mold support; bringing the first mold support and the second moldsupport together in a second position, the first mold and the first diebeing brought together to form a subsequently formed article, the firstdie selectively subsequently forming a first altered cross sectionalregion in at least a first portion of the protrusion, forming a firstundercut in the first altered cross sectional region or between thefirst altered cross sectional region of the protrusion and the body, thefirst undercut proximate to an end of the protrusion, the first dieadapted to form a second altered cross sectional region in at least asecond portion of the protrusion, forming a second undercut, the secondundercut non-proximate to the end of the protrusion.
 21. The method ofclaim 20, wherein providing a first mold support comprises a pluralityof first molds, and subsequent to moving the first mold support relativeto the second mold support, bringing the first mold support and thesecond mold support together such that once at least one first mold andat least one second mold have been brought together to form the article,when the at least one first mold and the at least one first die are thenbrought together to form the subsequently formed article, another firstof the at least one mold and another of the at least one second mold aresubstantially simultaneously brought together to form another article.22. The method of claim 20, wherein the article is an orthodonticbracket.